Symmetric vhf source for a plasma reactor

ABSTRACT

The disclosure pertains to a capactively coupled plasma source in which VHF power is applied through an impedance-matching coaxial resonator having a folded structure and symmetrical power distribution.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/375,370, filed Aug. 20, 2010 entitled SYMMETRIC VHF SOURCE FOR A PLASMA REACTOR, by Kartik Ramaswamy, et al.

TECHNICAL FIELD

The disclosure pertains to a capactively coupled plasma source in which VHF power is applied through an impedance-matching coaxial resonator to an overhead electrode, and in which the coaxial resonator is folded to reduce its length, and VHF power is applied from a symmetrical feeder inside the folded coaxial resonator to enhance uniformity of plasma distribution.

BACKGROUND

A capacitively coupled plasma source for processing a workpiece, such as a semiconductive wafer, has a fixed impedance match element in the form of a coaxial resonator or tuning stub through which VHF power is applied to a discoid or cylindrically symmetrical overhead electrode. A VHF power generator is connected to the tuning stub at a point along its axis at which the RF impedance matches the impedance of the VHF power generator. One limitation of such a structure is that the coaxial tuning stub is exceptionally long, being on the order of a half wavelength of the VHF generator, which may be 0.93 meters for a VHF frequency of 162 MHz. Another limitation is that the plasma distribution produced by such a source tends to be skewed, or non-uniform in an azimuthal direction. As employed herein, the terms azimuthal and radial are employed to signify directions in a cylindrical structure that are mutually orthogonal: The term radial signifies a direction along a radial line whose origin is the cylindrical axis of symmetry. The term azimuthal signifies a direction of travel along a circumference of the cylindrical structure. Non-uniform plasma distribution in the azimuthal direction may be referred to as skew. Plasma distribution may be skewed because of asymmetrical features of the plasma reactor, such as a bend in the coaxial tuning stub, RF-feeding of the tuning stub from one side, the presence of a slit opening in one side of the chamber wall, and the presence of a pumping port in the floor of the chamber of the plasma reactor.

SUMMARY

A plasma reactor includes a vacuum chamber enclosure comprising a ceiling and a cylindrical side wall, the ceiling comprising a center electrode, a dielectric support ring around the center electrode and a workpiece support having a support surface facing the ceiling. The reactor further includes a coaxial resonator which includes (a) a hollow inner conductive cylinder coaxial with the cylindrical side wall and having a bottom edge contacting the center electrode, (b) a hollow outer conductive cylinder coaxial with and surrounding the inner conductive cylinder and having a bottom edge on the dielectric support ring, the inner and outer conductive cylinders having respective circular top edges, (c) an annular conductor extending between and electrically contacting the respective circular top edges of the inner and outer conductive cylinders, and (d) a hollow center conductive cylinder coaxial with the inner and outer conductive cylinders and located between the inner and outer conductive cylinders, and having a bottom edge contacting the center electrode, the center conductive cylinder having a top edge facing and spaced from the annular conductor by an axial gap length. A VHF power generator is connected to the center conductor by a power coupler extending through the interior of the inner cylindrical conductor.

In accordance with one embodiment, the power coupler includes (a) an axial center conductor connected at a first end to the VHF generator and extending through the interior of the hollow inner conductive cylinder to a second end thereof at a selected axial location, (b) plural respective openings through the inner cylindrical conductor and coinciding with a circular plane at the selected axial location, and (c) plural respective spoke conductors extending radially from the second end of the axial center conductor through the plural respective openings and terminating at and contacting the center conductive cylinder, the plural respective spoke conductors being symmetrically distributed.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the exemplary embodiments of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be appreciated that certain well known processes are not discussed herein in order to not obscure the invention.

FIGS. 1A and 1B depict a plasma reactor in accordance with a first embodiment.

FIGS. 2A and 2B depict a VHF power coupler in accordance with another embodiment.

FIGS. 2C and 3 are cross-sectional views of the axial and spoke conductors, respectively, in the VHF power coupler of FIGS. 2A and 2B.

FIG. 4 depicts how the geometry of the resonator is defined for optimum resonance.

FIG. 5 depicts a plasma reactor in accordance with an alternative embodiment.

FIGS. 6 and 7 depict a plasma reactor in accordance with a further alternative embodiment.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

DETAILED DESCRIPTION

FIG. 1A depicts a plasma reactor having a capacitively coupled plasma source. The reactor has a chamber 100 enclosed by a cylindrical side wall 105, a ceiling 110 and a floor 115. The ceiling 110 includes a disc shaped ceiling electrode 120 surrounded by a dielectric ring 125. A workpiece support pedestal 130 supports a workpiece such as a semiconductor wafer 135 to be processed. VHF plasma source power is applied to the ceiling electrode 120 in a manner described below. The ceiling electrode 120 serves as a gas distribution showerhead, having gas injection orifices 140 in its bottom surface 120 a facing the interior of the chamber 100. The orifices 140 may be grouped into radially inner and outer gas injection zones 140 a, 140 b that are supplied by gas from internal inner and outer gas manifolds 145 a, 145 b within the ceiling electrode 120. Internal coolant passages 150 within the ceiling electrode 120 facilitate heat exchange with the ceiling electrode 120. The reactor further includes inner and outer plasma steering magnets or coil windings 155, 160. An RF bias power generator 165 is coupled through an RF impedance match element 170 to an internal electrode 175 within the workpiece support pedestal 130.

Plasma source power is applied to the ceiling electrode 120 from a VHF power generator 190 through a fixed impedance matching element. In certain embodiments described herein, the fixed impedance match element embodies a folded coaxial resonator 195, whose length is about half that of the basic coaxial tuning stub mentioned previously herein. This provides an advantageous reduction in size and increased access and serviceability. Specifically, the physical length of the folded coaxial resonator 195 is about a quarter wavelength at the frequency of the VHF generator 190.

The folded coaxial resonator 195 includes an inner conductive hollow cylinder 200 that is coaxial with the ceiling electrode 120. The inner conductive hollow cylinder 200 has a circular bottom edge 200 a electrically contacting the top surface of the ceiling electrode 120. The folded coaxial resonator 195 further includes an outer conductive hollow cylinder 205 having a circular bottom edge 205 a contacting the top surface of the dielectric ring 125. The inner and outer conductive cylinders 200, 205 are of at least approximately the same axial length, so that their circular top edges 200 b, 205 b are at the same height above the ceiling electrode 120. The folded coaxial resonator 195 also includes a planar conductive annulus 210 resting upon and electrically connecting the circular top edges 200 b, 205 b of the inner and outer conductive hollow cylinders 200, 205. The folded coaxial resonator 195 further includes a center conductive hollow cylinder 215 coaxial with the inner and outer hollow conductive cylinders 200, 205 and located between them. Preferably, the radius of the center conductive hollow cylinder 215 may be the geometric mean of the radii of the inner and outer hollow conductive cylinders 200, 205. The center conductive hollow cylinder 215 has a circular bottom edge 215 a resting on and in electrical contact with the top surface of the ceiling electrode 120.

A VHF power coupler 220 conducts VHF power from the VHF generator 190 to the center hollow conductive cylinder 215. Thus, the center hollow conductive cylinder 215 is the RE hot center conductor of the folded coaxial resonator 195, while the inner and outer hollow conductive cylinders 200, 205 together with the planar conducive annulus 210 are analogous to a grounded outer conductor of a simple coaxial resonator. The electrical connection of the bottom circular edges 200 a, 215 a to the ceiling electrode 120 provides the requisite D.C. short, equivalent to the D.C. short at the end of a simple (unfolded) coaxial tuning stub.

As shown in FIG. 1A, the VHF power coupler 220 includes an axial conductor 222 extending through a top portion of the hollow inner cylinder 200 from a top end 222 a outside of the cylinder 200 to a bottom end 222 b inside of the inner cylinder 200. A first spoke conductor 224 a extends radially from the axial conductor bottom end 222 b through a hole 226 a in the inner cylinder 200 to the center cylinder 215. As depicted in FIG. 1B, there are a plurality of spoke conductors 224 a, 224 b, 224 c, symmetrically arranged and extending radially from the axial conductor bottom end 222 b, through respective holes 226 a, 226 b, 226 c in the inner cylinder 200 and to the center cylinder 215 to which their outer ends are electrically connected. In the embodiment depicted in FIGS. 1A and 1B, there are three spoke conductors 224 disposed at 120 degree intervals, although any suitable number n of spoke conductors 224 may be provided at 360/n degree intervals.

Conduits and conductors for various utilities extend through the hollow inner cylinder 200. These include electric conductors 250, 252 carrying D.C. current to the plasma steering magnet 155, gas lines 254, 256 carrying process gas to the inner and outer gas manifolds 145 a, 145 b, and coolant conduits 258, 260 carrying coolant to and from the internal coolant passages 150. The interior of the inner cylinder 200 is devoid of electric fields, so that arcing or electrical breakdown of these utility lines is avoided or minimized.

In preferred embodiments, the VHF power coupler 220 is provided as a coaxial structure in which the axial conductor 222 and each of the spoke conductors 224 is a coaxial transmission line including a center conductor that is RF hot, surrounded by a grounded outer conductor or shield. This coaxial structure is depicted in FIGS. 2A and 2B, and is compatible with the field-free environment of the interior of the inner hollow conductive cylinder 200. In the embodiment of FIGS. 2A and 2B, the axial conductor 222 consists of a center axial conductor 222-1 connected to the output of the VHF generator 195, and a grounded outer axial conductor 222-2 surrounding the center axial conductor. FIG. 2C depicts a cross-sectional view of the axial conductor 222.

Each of the spoke conductors 224 a, 224 b, 224 c embodies a coaxial transmission line structure. Thus, the spoke conductor 224 a consists of a center spoke conductor 224 a-1 and an outer spoke conductor 224 a-2 surrounding the center spoke conductor 224 a-1. The center spoke conductor 224 a-1 extends radially from the axial center conductor 222-1 and terminates at and is electrically connected to the center cylinder 215. The center spoke conductor 224 a-1 is RF hot by reason of its connection to the axial center conductor 222-1. The outer spoke conductor 224 a-2 extends from the grounded axial outer conductor 222-2 and is terminated at (and electrically connected to) the inner cylinder 200. The center spoke conductor 224 a-1 passes through the hole 226 a (without contacting the inner conductive cylinder 200) to contact the center conductive cylinder 215.

The structure of each of the spoke conductors 224 a, 224 b, 224 c is the same. Thus, the spoke conductor 224 b consists of a center spoke conductor 224 b-1 and an outer spoke conductor 224 b-2 surrounding the center spoke conductor 224 b-1. The center spoke conductor 224 b-1 extends radially from the axial center conductor 222-1 and terminates at the center cylinder 215. The center spoke conductor 224 b-1 is RF hot by reason of its connection to the axial center conductor 222-1. The outer spoke conductor 224 b-2 extends from the grounded axial outer conductor 222-2 and is terminated at (and electrically connected to) the inner cylinder 200, while the center spoke conductor 224 b-1 passes through the hole 226 b (without contacting the inner conductive cylinder 200), to contact the center conductive cylinder 215.

In like manner, the spoke conductor 224 c consists of a center spoke conductor 224 c-1 and an outer spoke conductor 224 c-2 surrounding the center spoke conductor 224 c-1. The center spoke conductor 224 c-1 extends radially from the axial center conductor 222-1 and terminates at the center cylinder 215. The center spoke conductor 224 c-1 is RF hot by reason of its connection to the axial center conductor 222-1. The outer spoke conductor 224 c-2 extends from the grounded axial outer conductor 222-2 and is terminated at (and electrically connected to) the inner cylinder 200, while the center spoke conductor 224 c-1 passes through the hole 226 c (without contacting the inner conductive cylinder 200) to contact the center conductive cylinder 215.

The plural spoke center conductors 224 a-1, 224 b-1 and 224 c-1 extend in the radial direction from the axial center conductor 222-1 to electrically contact the center conductive cylinder 215. The area of this contact defines a circular plane. The axial location of this circular plane is selected to be such that the electrical or RF impedance at this location matches the characteristic impedance of 224 a, 224 b and 224 c, respectively, at the frequency of the VHF generator 190. The characteristic impedance of the individual spoke conductors 224 a, 224 b and 224 c is selected such that their total impedance at the junction (222 b) matches the output impedance of the VHF generator 190 at the frequency of the VHF generator 190.

Preferably, the axial center conductor 222-1 has a radius r1 that is sufficient to enable the axial center conductor to carry a very high VHF current, typical of current at thousands of Watts of VHF power. For example, as depicted in FIG. 2C, the center conductor radius r1 may be on the order of a quarter inch (or more). The axial outer conductor 222-2 has an annular cross section with an inner radius r2. The characteristic (transmission line) impedance of the axial conductor 222 is determined by the ratio between r1 and r2 (in accordance with a well-known formula). This ratio is selected so that the transmission line characteristic impedance of the axial conductor 222 matches the output impedance of the VHF generator 190.

FIG. 3 is a cross-sectional view of the coaxial transmission line structure of the spoke conductor 224 a, and is typical of the other spoke conductors 224 b, 224 c. The center spoke conductor 224 a-1 has a circular cross-section of radius R1, while the outer spoke conductor 224 a-2 has an annular cross-section of inner radius R2. Preferably, the center spoke conductor radius R1 is sufficiently large to enable the spoke conductor 224 a to carry a very high VHF current, typical of current at thousands of Watts of VHF power. For example the radius R1 may be on the order of a quarter inch (or more). The characteristic impedance of the coaxial spoke conductor 224 a is determined by the ratio between R1 and R2. This ratio is selected so that the characteristic impedance of each spoke conductor 224 is n times the impedance of the VHF generator, where n is an integer and is the number of spoke conductors 224. This feature ensures that the overall impedance presented by combination of the n parallel spoke conductors 224 is the same as the VHF generator impedance. (In the illustrated embodiments, n=3.) The structure of all of the other spoke conductors 224 b, 224 c is similar to that of the spoke conductor 224 a depicted in FIG. 3.

In order for the folded coaxial resonator 195 to attain at least near-resonance at the frequency of the VHF generator 190, the electrical path length along the interior surface formed by the inner and outer hollow conductive cylinders 200, 205 and the conductive annulus 210 is an integral fraction of the wavelength of the VHF generator. Preferably, this fraction is one-half. Thus, as depicted in FIG. 4, the sum of the axial lengths a and c along the interior surfaces of the inner and outer conductive cylinders 200, 205, respectively, and the radial length b along the interior surface of the conductive annulus 210 is equal to the desired fraction (preferably, one half) of the VHF generator wavelength. However, exact resonance is not always attained by this arrangement of the lengths a, b, and c, the discrepancy arising from stray capacitances attributable to the folded geometry of the resonator. Such stray capacitances are compensated in order to attain nearly exact resonance in the folded coaxial resonator 195 by adjusting the gap distance d between the circular top edge 215 b of the center hollow conductive cylinder 215 and the conductive annulus 210. This adjustment is readily performed by the skilled worker by trial and error to optimize resonance by the folded coaxial resonator 195 at the VHF generator frequency. For example, a network analyzer may be employed in conventional fashion to monitor resonance while the distance d is changed by modifying the center hollow conductive cylinder 215.

FIG. 5 depicts an embodiment of the VHF power coupler 220 in which the axial outer conductor 222-2 terminates at an annular ground plane conductor 300 having a circular outer edge 305 connected to the inner conductive cylinder 200. The annular ground plane conductor 300 may include a bell-shaped center section 310. In the embodiment of FIG. 5, the annular ground plane conductor 300 may replace the grounded outer coaxial conductors 224 a-2, 224 b-2, 224 c-2 of the spoke conductors 224 a, 224 b, 224 c.

The VHF power coupler 200 with multiple spoke conductors 224 may be employed in cases where the resonator is not folded. FIGS. 6 and 7 depict such a case, in which a simple (unfolded) coaxial resonator (or coaxial tuning stub) 400 is a fixed impedance match element connected between the VHF generator 190 and the ceiling electrode 120. The coaxial resonator 400 consists of a hollow conductive center cylinder 215, a hollow conductive outer cylinder 205, and an annular conductor 210 providing a D.C. short between the center and outer conductive cylinders 215, 205. The VHF power coupler 200 in the embodiment of FIG. 6 includes an axial conductor 222 extending into and coaxial with the interior of the center conductive cylinder 215. The axial conductor 222 has a center conductor 222-1 and an outer conductor 222-2 coaxial with the center conductor 222-1. The axial center conductor 222-1 is connected at an exterior end to the VHF power generator 190. An opposite end of the axial center conductor 222-1, which may be referred to as the interior end, lies within the center hollow conductive cylinder 215 at a selected axial location. The axial outer conductor 222-2 is terminated near the selected axial location of the interior end of the axial center conductor.

Each of the spoke conductors 224 a, 224 b, 224 c, 224 d may have a coaxial structure including a center spoke conductor 224 a-1, 224 b-1, 224 c-1, 224 d-1, respectively, surrounded by an outer spoke conductor 224 a-2, 224 b-2, 224 c-2, 224 d-2, respectively. The interior end of the axial center conductor 222-1 provides a common terminal to which the plural spoke center conductors 224 a-1, 224 b-1, 2242 c-1, 224 d-1 are connected. The plural spoke center conductors 224 a-1, 224 b-1, 224 c-1, 224 d-1 extend in the radial direction from the axial center conductor 222-1 to electrically contact the center conductive cylinder 215. The area of this contact defines a circular plane. The axial location of this plane is selected to be such that the electrical or RF impedance at this location matches the impedance of the VHF generator 190.

As in embodiments previously described here, the ratio between the radii of the inner and outer conductors of the axial conductor 222 is selected to be such that the axial conductor 222 has a characteristic impedance matching that of the VHF generator. The ratios between the inner and outer conductors of each of the spoke conductors 224 is selected to be such that the characteristic impedance of each spoke conductor 224 is n times the VHF generator output impedance, where n is the number of spoke conductors 224. In the embodiment of FIGS. 6 and 7, n=4.

The spoke outer conductors 224 a-2, 2224 b-2, 224 c-2, 224 d-2 extend from the axial outer conductor 222-2 and form a grounded conductive enclosure. The spoke outer conductors 224 a-2, 2224 b-2, 224 c-2, 224 d-2 are terminated slightly away from the interior surface of the center conductive hollow cylinder 215 so as to not electrically contact the center conductive hollow cylinder 215.

The plural spoke conductors 224 a through 224 d provide an azimuthally symmetrical distribution of VHF power to the center hollow conductive cylinder 215. The result is a more symmetrical distribution of VHF plasma source power on the ceiling electrode 120 and therefore a more uniform distribution of plasma ion density over the workpiece support pedestal 130.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. 

What is claimed is:
 1. A plasma reactor comprising: a vacuum chamber enclosure and a center electrode; a coaxial resonator comprising: (a) a hollow inner conductive cylinder coaxial with said center electrode and having a bottom edge contacting said center electrode; (b) a hollow outer conductive cylinder coaxial with and surrounding said inner conductive cylinder and having a bottom edge insulated from said center electrode, said inner and outer conductive cylinders having respective circular top edges; (c) an annular conductor extending between and electrically contacting said respective circular top edges of said inner and outer conductive cylinders; (d) a hollow center conductive cylinder coaxial with said inner and outer conductive cylinders and located between said inner and outer conductive cylinders, and having a bottom edge contacting said center electrode, said center conductive cylinder having a top edge facing an spaced from said annular conductor by an axial gap length; and a VHF power generator coupled to said center conductor.
 2. The reactor of claim 1 further comprising a connection between said outer cylindrical conductor and ground.
 3. The reactor of claim 1 wherein a sum of the axial lengths of said inner and outer conductive cylinders and a radial length of said annular conductor is at least approximately equal to an integral fraction of a wavelength of the frequency of said VHF generator.
 4. The reactor of claim 3 wherein said integral fraction is one-half.
 5. The reactor of claim 3 wherein said axial gap length is selected to optimize resonance of said coaxial resonator at the frequency of said VHF generator.
 6. The reactor of claim 1 wherein said center cylindrical conductor has a radius that is a geometric mean of the radii of said inner and outer conductive cylinders.
 7. The reactor of claim 1 wherein said VHF generator is coupled to said center conductor by a power coupler extending from said VHF power generator to said center conductor, wherein said power coupler comprises: an axial center conductor connected at a first end to said VHF generator and extending through the interior of said hollow inner conductive cylinder to a second end thereof at a selected axial location; plural respective openings through said inner cylindrical conductor and coinciding with a circular plane at said selected axial location; plural respective spoke conductors extending radially from said second end of said axial center conductor through said plural respective openings and terminating at and contacting said center conductive cylinder, said plural respective spoke conductors being symmetrically distributed.
 8. The reactor of claim 7 wherein said selected axial location corresponds to an impedance presented to said power coupler matching an output impedance of said VHF generator.
 9. The reactor of claim 7 wherein said power coupler further comprises: an axial grounded outer conductor coaxial with and surrounding said axial conductor of said power coupler; plural respective grounded spoke outer conductors coaxial with and around respective ones of said plural spoke conductors, and terminating at said inner cylindrical conductor, said axial grounded outer conductor and said plural grounded spoke outer conductors being joined together near, said second end of said axial center conductor.
 10. The reactor of claim 7 wherein said power coupler further comprises: an axial grounded outer conductor coaxial with and surrounding said axial conductor of said power coupler; a grounded conductive plane extending parallel to and facing said plural spoke conductors.
 11. The reactor of claim 1 wherein said center electrode comprises a gas distribution plate comprising plural interior gas passages and plural exterior gas ejection orifices on a bottom surface thereof, said reactor further comprising: a process gas source; hollow gas lines coupled between said process gas source and said gas distribution plate, said gas lines extending through the interior of said inner conductive cylinder.
 12. A plasma reactor comprising: a vacuum chamber enclosure comprising a ceiling and a cylindrical side wall, said ceiling comprising a center electrode and a dielectric support ring around said center electrode; a workpiece support having a support surface facing said ceiling; a coaxial resonator comprising: (a) a hollow outer conductive cylinder coaxial with said cylindrical side wall and having a bottom edge on said dielectric support ring; (b) a hollow center conductive cylinder coaxial with said inner and outer conductive cylinders and located between said inner and outer conductive cylinders, and having a bottom edge contacting said center electrode, said center conductive cylinder having a top edge facing an spaced from said annular conductor by an axial gap length; a VHF power generator; a power coupler extending from said VHF power generator to said center conductor, and comprising: an axial center conductor connected at a first end to said VHF generator and extending through the interior of said hollow center conductive cylinder to a second end thereof at a selected axial location; plural respective spoke conductors extending radially from said second end of said axial center conductor and terminating at and contacting said center conductive cylinder in a circular plane at said selected axial location, said plural respective spoke conductors being symmetrically distributed.
 13. The reactor of claim 12 wherein said selected axial location corresponds to an impedance presented to said power coupler matching an output impedance of said VHF generator.
 14. The reactor of claim 12 wherein said power coupler further comprises: an axial grounded outer conductor coaxial with and surrounding said axial conductor of said power coupler; plural respective grounded spoke outer conductors coaxial with and around respective ones of said plural spoke conductors, said axial grounded outer conductor and said plural grounded spoke outer conductors being joined together near said second end of said axial center conductor.
 15. The reactor of claim 12 wherein said power coupler further comprises: an axial grounded outer conductor coaxial with and surrounding said axial conductor of said power coupler; a grounded conductive plane extending parallel to and facing said plural spoke conductors. 